2025-01-14

Evaporator (2nd Generation) (Remove and Replace)

Correction code 18201052

2025-01-14: Added Note on separately adding correction code 18200102 and inserted cross references to nested procedures.
2023-08-01: Updated with content from re-validation.

Note

This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate activity to the Service Visit.

Removal

Open all four doors and lower the windows.
Remove the LH front seat. See Seat Assembly - 1st Row - LH (Remove and Install).
Remove RH front seat. See Seat Assembly - 1st Row - RH (Remove and Replace).
Recover the refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
Fully lower and extend steering column.
Power off the vehicle via the touchscreen.
Disconnect 12V power. See Disconnect 12V Power.
Remove center console. See Center Console Assembly (Remove and Replace).
Remove LH IP side cover.

Note
4x clips, 1x connector.
Remove LH middle A-pillar trim.

Note
2x clips.
Remove LH lower IP trim.

Note
1x screw, T20, 2 Nm, 9x clips.
Remove LH lower A-pillar trim.

Note
4x clips, The number of clips securing the trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim.
Remove RH IP side cover.

Note
4x clips, 1x connector.
Remove RH middle A-pillar trim.
Remove RH instrument panel lower assembly.

Note
13x clips.
Remove glove box lower trim.

Note
6x clips.
Remove glove box from IP carrier.

Note
6x screws, T20, 2.3 Nm, 3x connectors.
Remove RH footwell cover.

Note
2x screws, T20, 2 Nm, 1x connector.
Remove RH lower A-pillar trim.

Note
4x clips, The number of clips securing the trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim.
Remove LH shock tower cover.

Note
4x push clips.
Remove RH shock tower cover.

Note
4x push clips.
Remove LH side wiper arm.

Note
1x nut, 17mm, 31 Nm.
Remove RH side wiper arm.

Note
1x nut, 17mm, 31 Nm.
Remove cowl screen panel.

Note
4x push clips, 2x end tabs .
Remove fuse box cover.

Note
2x tabs, push tabs inwards and remove fuse box cover.
Remove 12V supply cable to DCDC.

Note
1x nyloc nut, 13mm, 12 Nm, 1x clip, Discard nyloc nut.
Release clips securing 12V battery supply cable to fuse box and strut tower cross beam.

Note
3x clips.
Disconnect pyrotechnic fuse connector.

Note
1x connector, Gently lift up orange lock tab to release connector.
Remove bolts securing fuse box to body.

Note
2x bolts, 10mm, 6 Nm.
Release fuse box from body.

Note
2x tabs, Slide fuse box to RH side to release tabs and then lift.
Disconnect remaining connectors from bottom of fuse box.

Note
3x connectors, Depress locking tabs on sides of flip type connector and flip lever on connector to reseal.
Remove clip securing harness to LH shock tower brace.
Remove wiper motor fastener mounted to LH shock brace.

Note
1x bolt, 10mm, 6 Nm.
Remove LH air suspension reservoir bracket from LH shock brace .

Note
2x bolts, 10mm, 6 Nm.
Remove AC line bracket bolt on RH shock brace.

Note
1x bolt, 10mm, 6 Nm.
Remove air reservoir bracket mounting bolts from RH shock brace .

Note
2x bolts, 10mm, 6 Nm.
Remove LH shock tower brace.

Note
1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm.
Remove RH shock tower brace.

Note
1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm.
Remove wiper motor.

Note
3x bolts, 10mm, 6 Nm, 1x connector.
Remove screws securing air suspension reservoir to bracket.

Note
2x screws, T25, 2.5 Nm.
Set air suspension reservoir aside for access.

Note
Maneuver below AC line.
Remove fasteners securing TXV to evaporator.

Note
2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install.
Disconnect A/C hoses and TXV from HVAC unit.

Note
Gently pull the lines away from the bulkhead/ HVAC box, be sure to retain the O-rings at the TXV.
Remove screw securing LH side of the top pad.

Note
1x screw, T20, 1 Nm.
Remove LH upper A-pillar trim panel.

Note
1x screw with washer, 7mm, 2 Nm, 1x connector, 2x locating tabs, 1x clip.
Remove the lower binnacle cover from the IP area of the vehicle.

Note
4x clips.
Remove screws securing top pad at binnacle area.

Note
2x screws, T20, 1 Nm.
Remove screw securing RH side of top pad.

Note
1x screw, T20, 1 Nm.
Remove RH upper A-pillar trim panel.

Note
1x screw, 7mm, 2 Nm, 1x connector.
Disconnect connectors from RH side of DAS ECU.

Note
7x connectors, DAS 2.0 has 4x connectors.
Remove fasteners securing DAS ECU to cross car beam.

Note
4x nuts, 8mm, 5 Nm, Discard after removal.
Disconnect connectors from LH side of Autopilot ECU and remove from vehicle.

Note
7x connectors.
Disconnect passenger airbag connectors.

Note
2x connectors, Release locking tab.
Remove the passenger airbag mounting bolts.

Note
2x bolts, 10mm, 10 Nm.
Cover the aluminum strip on the top pad and MCU bezel with tape for protection.
Release top pad at leading edge, from drivers outer finisher to inner finisher.

Note
8x clips.
Release the RH side of the top pad working from right to left.

Note
9x clips, Use caution to not crease aluminum trim when lifting top pad.
Release MCU ground strap.

Note
1x tab.
Release remaining clips, remove top pad from vehicle, and place onto protective surface.

Note
6x clips, Recommend assistance.
Remove defrost mesh grille assembly.

Note
10x clips.
Remove screws securing RH IP finisher.

Note
2x screws, T20, 2 Nm.
Release clips for the RH IP finisher and remove from vehicle.

Note
4x clips.
Release clips securing steering gap hider to IC bezel.

Note
2x clips.
Remove screws securing instrument cluster bezel to IP carrier and remove bezel.

Note
4x screws, T20, 2 Nm.
Remove screws securing LH inner IP finisher with vent to IP carrier.

Note
2x screws, T20, 2 Nm.
Release clips securing LH inner IP finisher with vent to the IP carrier and remove from vehicle.

Note
3x clips.
Install screws securing LH outer IP finisher to the IP carrier.

Note
3x screws, T20, 2.3 Nm.
Remove LH outer IP finisher from IP carrier.

Note
2x clips .
Remove screws securing airbag to steering wheel.

Note
2x screws, T25, 7 Nm, The screws will remain inside the steering wheel, If required rotate the steering wheel to gain access to screws, Afterwards return steering wheel to straight and center position.
Carefully release the driver's airbag from the steering wheel assembly .

Note
3x connectors, disconnect the airbag and steering wheel controls.
Remove bolt that secures the steering wheel to the column.

Note
1x patch bolt, 10mm Allen, 80 Nm, Discard after removal.
Position the wheels straight ahead and mark the steering wheel relative position to the column.
Remove steering wheel.
Tape the clockspring cassette to prevent rotation.

Note
Do not rotate the clockspring.
Rock SCCM back and forth to release from column.
Release harness connector from SCCM and remove SCCM.

Note
1x connector, Remove black locking tab then depress connector release tab to release connector, Locking tab is one time use discard after removal.
Remove LH footwell cover.

Note
2x screws, T20, 2 Nm, 1x connector.
Remove passenger knee airbag.

Note
2x nuts, 10mm, 10 Nm, 1x connector, Discard nuts after removal.
Disconnect steering column motor connectors.

Note
2x connectors.
Mark the steering column relative position to the lower shaft joint.
Remove bolt securing lower shaft to steering column.

Note
1x bolt, 13mm, 30 Nm.
Release steering column from lower shaft.

Note
Slide joint down lower shaft.
Remove fasteners securing steering column to cross car beam.

Note
2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm.
Remove steering column from vehicle.
Remove fasteners securing instrument cluster to IP carrier.

Note
4x screws, T20, 2 Nm.
Disconnect the electrical connectors from the rear of the instrument cluster and remove from IP carrier.

Note
3x connectors, tilt the IC away from the IP carrier to access connections, Take care not to put excessive strain on the wiring and connectors to the IC (1x chime connector pulls straight out, 1x flip lock type connector, 1x coaxial connector, release tab is on the underside of the connector), After removal place the IC on ESD safe surface.
Remove the MCU mounting screws.

Note
4x screw, T25, 4.5 Nm, Note locations of washers if present.
Tilt the MCU out from the IP carrier at the top in order to access connectors.

Note
Caution: Do not pull on harnesses as it can damage the connectors.
Disconnect all electrical connections from the MCU.

Note
13x connectors, Gently tilt the top of the MCU/touch screen for access, recommend assistance. All connectors are equipped with locking tabs that must be depressed prior to disconnect, Avoid putting excessive tension on the connectors and wiring harness during removal, (number of connectors may vary depending on vehicle configuration and MCU part number revision).
Release clips securing tweeter harnesses to the IP carrier near LH and RH A-pillars.

Note
2x clips.
Remove the clips securing the dash harness to the IP carrier .

Note
2x clips.
Remove fasteners securing IP carrier to cross car beam.

Note
15x screws, T20, 2 Nm.
Pull the IP carrier forward for better access for speaker and edge clip removal.

Note
Take care to avoid stressing the connectors to the dash speakers and avoid damaging components in the process of moving the IP carrier forward for better access to edge clips and connections.
Remove RH side dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector.
Remove center dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector.
Remove LH dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector.
Remove IP carrier from vehicle.

Note
Recommend assistance, Lift up air duct from HVAC assembly, 1x center dash speaker tape to duct.
Disconnect headliner harness at LH A-pillar and release from vehicle.

Note
3x connectors, 1x clip.
Remove cross car beam harness connectors at LH lower A-pillar.

Note
7x connectors, Only release connectors that run to the harness on the cross car beam.
Disconnect the cross car beam harness connectors at the RH lower A-pillar.

Note
7x connectors, Only release connectors that run to the harness on the cross car beam.
Remove fasteners securing cross car beam to HVAC assembly.

Note
3x bolts, 10mm, 10 Nm.
Remove fasteners securing cross car beam to vehicle.

Note
7x bolts, 13mm, 27 Nm.
Remove cross car beam from vehicle.

Note
Recommend assistance, Exercise caution when removing the cross car beam, the brake switch is attached to the cross car beam and is susceptible to failure.
Disconnect thermal controller.

Note
4x connectors, 1x edge clip.
Disconnect HVAC blower assembly and RKE connector and release harness clip.

Note
2x connectors, 2x edge clips.
Remove fasteners securing HVAC assembly to the body.

Note
5x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm.
Release HVAC drain hose from HVAC assembly.

Note
1x hose connection, Place a shop towel underneath the drain hose prior to disconnecting.
Disconnect sensor from RH lower air duct on HVAC assembly.

Note
1x connector.
Remove the fasteners securing the RH lower air duct to the HVAC assembly.

Note
2x screws, PH2, 1 Nm.
Remove the RH lower air duct from the HVAC assembly.

Note
Lower left slide of duct and slide out to the left to release from HVAC assembly.
Remove the fasteners securing the HVAC assembly cross brace.

Note
2x screws, PH2, 1 Nm.
Remove the HVAC assembly cross brace.

Note
Gently push brace to the left to release from HVAC box on RH side, Pull the brace towards the rear for the vehicle then side out to the right to release from HVAC assembly.
Remove fasteners securing the PTC heater to the HVAC assembly.

Note
3x screws, PH2, 1 Nm.
Remove the PTC heater from the HVAC assembly.

Note
Slide PTC heater out to the left while taking care not to strain the HV cables, Gently move the PTC heater and HV cables behind the HVAC assembly so it can be removed from the vehicle, Take necessary measures to protect the PTC heater and its cables so it can be easily moved out of the way during main body harness replacement as needed.
Remove the HVAC assembly from the vehicle.

Note
Recommend assistance.
Remove the foam spacer from the HVAC pipe inlet area.

Note
Reuse if not damaged.
Remove lower evaporator cover.

Note
9x screws, PH2, 2 Nm.
Remove upper evaporator cover.

Note
6x screws, PH2, 2 Nm.
Remove the screws for the HVAC box for the evaporator inlet pipe.

Note
2x screws, PH2, 2 Nm.
Remove evaporator from HVAC box.
With the evaporator on the bench remove the plastic mounting bracket.

Note
3x screws, PH2, 2 Nm.

Installation

Install the evaporator mounting bracket on to the new evaporator.

Note
2x screws, PH2, 2 Nm.
Install evaporator into HVAC box.
Install the upper evaporator cover onto the HVAC box assembly.

Note
6x screws, PH2, 2 Nm.
Install the lower evaporator cover onto the HVAC box assembly.

Note
9x screws, PH2, 2 Nm.
Install the HVAC evaporator inlet pipes onto the HVAC box assembly.

Note
2x screws, PH2, 2 Nm.
Install foam seal onto HVAC box.

Note
Reuse if not damaged.
Place the HVAC assembly back into the vehicle for installation.

Note
Recommend assistance, Move all loose harness connections out of the way to prevent damage while re-installing the HVAC assembly in the vehicle.
Route the PTC heater to the HVAC assembly for installation and slide into HVAC assembly.
Install the fasteners securing the PTC heater to the HVAC assembly.

Note
3x screws, PH2, 1 Nm.
Position the HVAC assembly cross brace for installation to the HVAC assembly.
Install the fasteners securing the HVAC assembly cross brace to the HVAC assembly.

Note
2x screws, PH2, 1 Nm.
Position the HVAC assembly RH lower air duct for installation.
Install the fasteners securing the RH lower air duct to the HVAC assembly.

Note
2x screws, PH2, 1 Nm.
Connect sensor for RH lower air duct on HVAC assembly.

Note
1x connector.
Move HVAC assembly into position for installation and secure the drain hose.

Note
1x hose connection.
Install fasteners securing the HVAC assembly to the body.

Note
5x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm.
Connect HVAC blower assembly and RKE, and secure harness clip.

Note
2x connectors, 2x edge clips.
Connect thermal controller.

Note
4x connectors, 1x edge clip.
Connect A/C Lines with TXV to evaporator at the bulkhead.

Note
2x bolts, T30, 6 Nm, Install new O-rings prior to installation.
Place air suspension reservoir into position.
Loosely install air suspension reservoir brackets.

Note
2x screws, T25, 2.5 Nm.
Secure air suspension reservoir brackets.

Note
2x screws, T25, 2.5 Nm.
Install LH shock tower brace.

Note
1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm.
Install RH shock tower brace.

Note
2x bolts, 13mm, 20 Nm, 1x bolt, 13mm, 20 Nm.
Install air suspension reservoir bracket mounting fasteners to RH shock brace .

Note
2x bolts, 10mm, 6 Nm.
Install AC line bracket bolt on RH shock brace.

Note
1x bolts, 10mm, 6 Nm.
Install wiper motor fastener mounted to LH shock brace.

Note
1x bolt, 10mm, 6 Nm.
Install air suspension reservoir bracket mounting fasteners to LH shock brace .

Note
2x bolts, 10mm, 6 Nm.
Clip wire harness to LH shock brace.

Note
1x fir tree clip.
Secure air suspension reservoir brackets.

Note
2x screws, T25, 2.5 Nm.
Place fuse box into vehicle and reconnect harness connectors.

Note
3x connectors.
Position fuse box onto body.

Note
2x tabs, Slide the fuse box to LH to attach the tabs into crossbar.
Install bolts securing fuse box to body.

Note
2x bolts, 10mm, 6 Nm.
Reconnect pyrotechnic fuse connector.

Note
1x connector, Be sure to secure locking clip.
Secure clips holding 12V battery supply cable to fuse box and strut tower beam.

Note
3x clips.
Install new nut securing 12V supply cable to DCDC.

Note
1x nyloc nut, 13mm, 12 Nm, Install new nyloc nut.
Install fuse box cover.

Note
2x clips.
Install wiper motor.

Note
3x bolts, 10mm, 6 Nm, 1x connector.
Install cowl screen.

Note
4x push clips, 2x end tabs.
Install LH shock tower cover.

Note
4x push clips.
Install RH shock tower cover.

Note
4x push clips.
Install wiper arms.

Note
2x nuts, 17mm, 31 Nm.
Position cross car beam into the vehicle for installation.

Note
Recommend assistance, Exercise caution when installing the cross car beam, the brake switch is attached to the cross car beam and is susceptible to failure, Take care not to damage any surrounding components while placing the cross car beam into the vehicle.
Install fasteners securing cross car beam to HVAC assembly.

Note
3x bolts, 10mm, 10 Nm.
Install fasteners securing cross car beam to vehicle.

Note
7x bolts, 13mm, 27 Nm.
Connect headliner harness at LH A-pillar.

Note
3x connectors, 1x clip.
Connect cross car beam harness connectors at LH lower A-pillar.

Note
7x connectors, (2x coaxial brown and white at tuner)(2x coaxial blue)(1x coaxial purple)(2x connectors gray), Connectors at tuner are routed through amp and tuner bracket.
Connect cross car beam harness to main harness connectors at RH lower A-pillar.

Note
7x connectors.
Install IP carrier into vehicle.

Note
Recommend assistance.
Install center dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers.
Install RH dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers.
Install LH dash speaker.

Note
2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers.
Install fasteners securing IP carrier to cross car beam.

Note
15x screws, T20, 2 Nm,.
Secure harness clips to the IP carrier.

Note
2x clips .
Secure tweeter harnesses to the IP carrier near LH and RH A-pillars.

Note
2x clips.
Place steering column into vehicle for installation.
Install fasteners securing steering column to cross car beam.

Note
2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm.
Connect harness connectors for steering column motors.

Note
2x connectors.
Connect steering column to lower steering shaft joint.

Note
Slide joint up onto lower shaft, Ensure that the previously indexed paint marks align between the lower steering column and shaft joint.
Install bolt securing lower shaft to steering column.

Note
1x bolt, 13mm, 30 Nm.
Install passenger knee airbag.

Note
2x nuts, 10mm, 10 Nm, 1x connector, Install new fasteners, Engage red locking tab to secure connection.
Install LH footwell cover.

Note
2x screws, T20, 2 Nm, 1x connector.
Connect harness to steering column control module.

Note
1x connector, Install new retaining clip.
Slide steering column control module over upper steering column.

Note
Gently jiggle the SCCM while pressing it onto the column if needed.
Remove tape previously applied to the clockspring.

Note
Do not rotate the clockspring.
Install steering wheel.

Note
Ensure the position of the steering wheel matches the index marks previously made on the column and the wheel.
Install bolt securing steering wheel to steering column.

Note
1x patch bolt, 10mm Allen, 80 Nm, Install new patch bolt.
Connect drivers airbag and steering wheel control connectors.

Note
3x connectors.
Place airbag assembly into steering wheel.
Install screws securing airbag to steering wheel.

Note
2x screws, T25, 7 Nm.
Connect Instrument cluster and place IC into position for installation.

Note
3x connectors, 2x alignment dowels.
Install the fasteners that secure the instrument cluster to the IP carrier.

Note
4x screws, T20, 2 Nm.
Position MCU into vehicle for installation.
Connect harness connectors to MCU.

Note
17x connectors, Number of connectors may vary depending on vehicle configuration and MCU part number revision.
Install bolts securing MCU to the IP carrier.

Note
4x screws, T25, 4.5 Nm.
Install RH IP finisher assembly and fasteners.

Note
2x screws, T20, 2 Nm, 6x clips.
Install LH inner IP finisher.

Note
3x clips.
Install screws securing LH inner IP finisher.

Note
2x screws, T20, 1 Nm.
Install screws securing LH outer IP finisher to the IP carrier.

Note
3x screws, T20, 2.3 Nm.
Install IC bezel and fasteners to the IP carrier.

Note
4x screws, T20, 2 Nm.
Install IC bezel and fasteners to the IP carrier.

Note
4x screws, T20, 2 Nm.
Install clips securing steering column gap hider to IC bezel.

Note
2x clips, Replace any damaged or missing clips prior to installation.
Install LH lower IP trim.

Note
1x screw, T20, 2 Nm, 9x clips, Replace any damaged or missing clips prior to installation.
Install the defrost mesh grille to IP carrier.

Note
10x clips, Replace any damaged or missing clips prior to installation.
Position the top pad into vehicle.

Note
Recommend assistance.
Install MCU ground strap to IP top pad.

Note
1x ground strap.
Install passenger airbag connectors.

Note
2x connectors, Engage locking tabs.
Remove protective tape from aluminum trim.
Fully seat top pad.

Note
23x clips, Make sure all clips are aligned and securely fastened.
Install LH upper A-pillar trim panel.

Note
1x screw, 7mm, 2 Nm, 1x connector.
Install RH upper A-pillar trim panel.

Note
1x screw, 7mm, 2 Nm, 1x connector.
Install the airbag mounting bolts.

Note
2x bolts, 10mm, 10 Nm.
Remove ECU from anti-static bag, position the new ECU for installation, and secure LH side ECU connectors.

Note
6x connectors.
Install fasteners securing Autopilot ECU.

Note
4x nuts, 8mm, 5 Nm, Install new nuts.
Connect RH side DAS ECU connectors.

Note
7x connectors, DAS 2.0 has 4x connectors, Connector "A" must be plugged in before connector "B" when reinstalling DAS ECU.
Install the center console. See Center Console Assembly (Remove and Replace).
Install the LH front seat. See Seat Assembly - 1st Row - LH (Remove and Install).
Install the RH front seat. See Seat Assembly - 1st Row - RH (Remove and Replace).
Connect 12V power. See Disconnect 12V Power
Perform a vacuum leak test and recharge the refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
Install LH lower A-pillar trim.

Note
4x clips, The number of clips securing the A-pillar sill trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim.
Install LH middle A-pillar trim.
Install LH IP side cover.

Note
4x clips, 1x connector.
Install RH lower A-pillar trim.

Note
4x clips, The number of clips securing the a pillar sill trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim.
Install RH middle A-pillar trim.
Install RH IP side cover.

Note
3x clips, 1x connector.
Install HEPA filter outlet duct.
Install HEPA filter inlet duct.

Note
2x tabs, One on each side.
Install clips securing HEPA filter inlet duct to cowl panel.

Note
3x push clips.
Secure drainage hoses to HEPA filter inlet duct.

Note
2x hoses.
Install RH under hood apron.

Note
9x clips.
Install LH underhood apron.

Note
9x clips.
Install rear underhood apron.

Note
8x clips.